Football and method of manufacturing same

ABSTRACT

The present development is directed to footballs and to methods for producing the same. More particularly, the disclosure is directed to a technique for readily and inexpensively manufacturing a football. The technique utilizes one or more molding operations and the formation of simulated seams on the ball.

BACKGROUND

The present disclosure relates generally to the field of sports balls or game balls. More particularly, the disclosure is directed to footballs, and methods for producing such.

Traditionally, footballs are produced by labor-intensive processes involving numerous operations, many of which are performed by hand. One of the most time consuming and tedious operations involves the assembly of a cover and placement of the cover onto a previously formed football carcass. Typically, a series of cover panels, usually four or five, are sewn together to form a pocket-like assembly. The assembly of sewn panels is then turned inside out, so that the finished face of the panels, i.e. the pebbled surface, is exposed outward. A football carcass is then inserted within the pocket or interior of the assembly, and the assembly closed to thereby contain the carcass. During the insertion operation, efforts are taken to align a valve stem from the carcass bladder with an opening in the cover assembly.

Closure of the assembly is typically performed by lacing together adjacent cover panels that previously formed the opening through which the carcass was inserted. One or more laces are threaded through a collection of holes formed along corresponding edges of two adjacent cover panels that formed the opening. If the holes were not previously formed in the cover panels, a hole forming operation must then be conducted prior to lacing. Lacing is then performed to effectively close the cover panel assembly.

Alternate methods for football construction have included adhesively bonding cover panels to a bladder and then applying lacing through holes in two adjacent panels, as described in U.S. Pat. No. 3,948,518. The use of a preformed lacing assembly was described in U.S. Pat. No. 4,869,504. An overmolding process was described in U.S. Pat. No. 5,181,717. In that overmolding process, a unitary skin or cover is molded onto a premanufactured carcass. Yet another approach was described in U.S. Pat. No. 5,888,157 in which various rubber layers and strips are placed about a wound bladder. The resulting assembly is then heated, preferably in a mold to form the football carcass. Next, a series of cover panels are adhesively attached to the carcass. A region of two adjoining cover panels is selected which is free of adhesive, and lacing is then inserted in corresponding cover holes at that region.

Although satisfactory in certain respects, a need still remains for a manufacturing process that is less labor intensive than the noted methods. Moreover, a need remains for a football that is more durable and less likely to exhibit tearing or peeling of cover panels that are glued to an underlying layer.

The previously noted U.S. Pat. No. 3,948,518 describes an assembly process whereby preformed panels having longitudinally extending ribs are used in forming a football. The outwardly extending ribs separate cover panels that are adhesively attached to the ball carcass. Thus, the ribs resemble “seams” as associated with certain footballs. Although this simplified construction approach provides some advantages over the relatively complicated typical football assembly processes, requiring the use of ribbed, preformed panels introduces other manufacturing complexities such as (i) ensuring that the panels are appropriately aligned on the carcass assembly so that the ribs extend longitudinally across the ball from one end to another, and (ii) ensuring that the alignment between the panels and the carcass is maintained during molding or other football manufacturing operations. In addition, the use of preformed panels with outwardly extending ribs, increases the overall cost of manufacturing the ball since the specific ribbed panels must be premade. After producing the ribbed panels, they must then be further stored or inventoried until their use in the football manufacture. All of these disadvantages add to the expense associated with manufacturing the football. Accordingly, there remains a need for an economical and relatively simple strategy for producing a football.

Additionally, aesthetics and the “feel” of a football are particularly important, especially when the football is used in competitive play. Although the footballs produced according to the noted patents may be acceptable for many applications, a need remains for a football with improved feel, yet which can be inexpensively manufactured.

BRIEF DESCRIPTION OF THE DISCLOSURE

In a first aspect, the present invention provides a method of forming a football. The method comprises forming a bladder adapted for use in a football. The method also comprises depositing a reinforcement layer on the bladder to thereby form a football carcass. The method further comprises providing a molding assembly having a molding surface that defines a collection of recessed channels. Each channel is adapted to form an outwardly projecting seam on a football when subjected to a molding operation. The method involves positioning a layer of a seam material between the molding surface and the carcass such that the layer of the seam material is immediately adjacent to a recessed channel in the molding surface. The method further comprises applying heat to the seam material thereby causing that material to adhere to the carcass and flow into the adjacent recessed channel and form one or more outwardly projecting seams on the carcass. The method further comprises securing a collection of cover panels to the carcass. The adjacent cover panels are separated by the outwardly projecting seams.

In yet another aspect, the present invention provides a method of forming a football. The method comprises providing a first molding surface and molding a bladder on the first molding surface. The method also comprises forming a fibrous reinforcement layer on the bladder. The method additionally comprises applying a lacing base to the reinforcement layer to thereby form a carcass. The method further comprises providing a second molding surface defining a collection of recessed channels adapted to form seams on the football. The method further comprises applying a layer of a seam material onto at least one of the second molding surface and the carcass such that the seam material is adjacent to a recessed channel. The method further comprises applying heat and pressure to the layer of the seam material to thereby cause the seam material to at least partially flow into the recessed channel and thereby form an outwardly projecting seam. The method further comprises applying a collection of cover panels onto the underlying carcass and alongside the seam. The method further comprises inserting laces into apertures defined in at least one cover panel. And, the method comprises applying markings or striping to the cover panels to thereby form the finished football.

In yet another aspect, the present invention provides a method of forming a football comprising forming an inflatable bladder. The method also comprises forming a reinforcement layer on the bladder to thereby form a carcass. The method additionally comprises providing a molding assembly sized and adapted to form a football. The molding assembly has a molding surface that defines a collection of recessed channels extending from one end of the mold to another opposite end of the mold. The method further comprises positioning a layer of a moldable material onto the molding surface such that the entirety of the molding surface is covered by the moldable material. The method further comprises placing the carcass in the molding assembly such that the layer of molding material is disposed between the carcass and the molding surface. The method additionally comprises closing the molding assembly. And, the method comprises applying heat and pressure to the carcass and the moldable material such that the material flows into the recessed channels defined in the molding surface to thereby form outwardly extending projections along the resulting intermediate football assembly. The method further comprises removing the intermediate football assembly from the molding assembly. And, the method comprises securing a collection of cover panels to the intermediate football assembly such that an outwardly extending projection separates adjacent cover panels.

There has thus been outlined, rather broadly, some of the more important features of the footballs and their methods of manufacturing disclosed herein in order that the detailed description thereof that follows may be better understood. There are, of course, additional features of the disclosure that will be described hereinafter and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the football and its manufacture disclosed herein in detail, it is to be understood that the disclosure is not limited in this application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The disclosed football and related method is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present development. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the development disclosed herein will be evident to one of ordinary skill in the art from the following description and figures, in which:

FIG. 1 is a partial exploded view of an assembly of layers used in a preferred embodiment football carcass.

FIG. 2 is a partial exploded view of a plurality of cover panels that are adjoined onto a carcass in a preferred embodiment football assembly.

FIG. 3 is another exploded view of further assembly of cover panels that are adjoined onto a carcass in a preferred embodiment football assembly.

FIG. 3A is a partial schematic cross section taken along line 3A-3A in FIG. 2.

FIG. 4 is a schematic flowchart illustrating assembly of a preferred embodiment carcass.

FIG. 5 is a flowchart illustrating assembly of a preferred embodiment intermediate football.

FIG. 6 is a flowchart illustrating assembly of a preferred embodiment football.

FIG. 7 is a detailed cross-sectional schematic of a molding assembly and intermediate ball assembly formed therein.

FIG. 8 is a detailed cross-sectional schematic of a preferred embodiment sports ball.

DETAILED DESCRIPTION

The preferred embodiment football and related method of manufacturing provides a significantly improved strategy for inexpensively producing a durable and wear resistant football exhibiting excellent aesthetics and “feel.”

A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present development, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.

Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

In a preferred embodiment, the present invention provides a unique and economical process for manufacturing a football and the football produced from that process. This process involves the use of particular molds that define channels or recesses that during manufacture of the football, form seams that extend longitudinally from one end of the football to the other. The seams are formed from thin layers of a material, generally referred to herein as seam members, that upon molding, flow into the channels or recesses defined in the mold surface and form outwardly projecting seams on the football or intermediate football. The thin layers can be either placed on the football carcass prior to molding, or placed in the mold, generally over the channels and recesses prior to ball molding. After formation of the longitudinally extending and outwardly projecting seams, cover panels are then applied onto the football. This unique strategy entirely avoids the problems and additional costs associated with using preformed panels with outwardly extending ribs that must be aligned on the ball, maintained in alignment during ball manufacture, and stored or inventoried prior to ball manufacture.

FIG. 1 illustrates a preferred embodiment assembly for forming a carcass of the preferred embodiment footballs described herein. Specifically, in FIG. 1, a mold surface 10 is illustrated. A bladder 20 is formed on or about the mold surface 10. The bladder defines an outer surface 22. Disposed on the outer surface 22 of the bladder 20 is a fibrous reinforcement layer 30. The fibrous reinforcement layer 30 defines an outer surface 32. A lacing base 40 is positioned on the outer surface 32 of the fibrous layer 30. The lacing base defines an optional longitudinal slit 42 which separates a collection of apertures 44 defined in the base 40. An optional foam layer 50 is disposed on the fibrous reinforcement layer and the lacing base 40. The foam layer defines an outer surface 52. Details and preferred materials of construction for each of these components are described in conjunction with the preferred methods of construction herein. This resulting collection of layers and components constitutes a preferred embodiment carcass of the footballs described herein.

Referring to FIGS. 2, 3, and 3A, further assembly of the carcass with cover panels and seam members is depicted. Specifically, FIG. 2 illustrates a carcass having an optional outer foam layer having outer surface 52 and a plurality of simulated seam members 60 extending longitudinally from one end of the carcass to the other. If a foam layer 50 is not used, the seam members 60 are disposed on the fibrous reinforcement layer 30 as shown in FIG. 1. Each seam member defines a first cover placement line 62 and a second cover placement line 64, both of which are described in greater detail herein. In a preferred embodiment, application of heat and pressure is used to cause the seam member to adhere to the underlying surface and to partially melt and form an outwardly raised projection. This outwardly raised projection, in a preferred embodiment of the present invention, provides a “seam” in the finished football. These aspects are described in greater detail herein. A collection of cover panels, each designated by 70, are positioned about the carcass. Each cover panel defines a first edge 72, a second edge 74 opposite from the first edge 72, an outer face 76 which typically includes pebbling, and an oppositely directed inner face 78. Upon placement of a cover panel 70 with the carcass, the inner face 78 is preferably in contact and is secured to the outer surface of the carcass. Preferably, the cover panels 70 are free of adhesive, and specifically, free of adhesive along their inner face 78. Each cover panel is secured to the carcass, and separated by a seam member, and preferably by an outwardly raised projection or “seam.” Each side of a seam of a seam member defines a cover placement line, along which an edge of a cover panel is preferably located. More specifically, placement of a cover panel 70 in association with the seam members is such that the first edge 72 of a cover panel 70 preferably is aligned along the first cover placement line 62 defined on a simulated seam member 60. And, the second edge 74 of a cover panel 70 is positioned such that it is aligned along the second cover placement line 64 defined on a simulated seam member 60. This is depicted schematically in FIG. 3A which is a partial cross section of the assembly in FIG. 2, taken across line 3A-3A. Referring to FIG. 2, thus, specifically for cover panel 70 a for example, the first edge 72 a is placed upon and aligned along the first cover placement line 62 a of the simulated seam member 60, and the second edge 74 a of the cover panel 70 a is placed upon and aligned along the second cover placement line 64 a (not shown). Likewise, for the cover panel 70 b, the first edge 72 b is placed upon and aligned along a first cover placement line 62 b (not shown) and the second edge 74 b is placed upon and aligned along the second cover placement line 64 b.

Referring to FIG. 3, placement of cover panels on the remaining portion of the carcass and incorporation of the lacing base 40 is illustrated. Specifically, it can be seen that the lacing base 40 is positioned upon and generally centered upon a simulated seam member 60. Preferably, the slit 42 defined in the lacing base 40 is centered upon the seam member 60 and preferably aligned such that it is parallel with the longitudinal axis of the seam member 60. A plurality of apertures 75 c is defined along an edge of the cover panel 70 c. Similarly, another plurality of apertures 75 d are defined along a corresponding edge of cover panel 70 d. The apertures are sized and numbered such that the corresponding sets of apertures 75 c and 75 d overlap and are aligned with the two sets of apertures 44 of the fabric base 40 upon placement and positioning of cover panels 70 c and 70 d on the carcass.

Upon attachment of the cover panels to the seam strips and underlying carcass or foam layer, additional finishing components can be included in the assembly to complete the preferred embodiment football. Lacing is inserted through the noted sets of apertures, i.e. 75 c, 44, and 75 d. In addition markings, indicia, labels, striping, logos, and/or other designations can be applied to the football.

Various preferred methods of manufacturing are also provided. These improved manufacturing methods are particularly suited for high volume commercial production objectives in which it is desirable to inexpensively produce a high quality, low defect, football with consistent properties such as attractive aesthetics and good “feel.”

Referring to FIG. 4, in a preferred embodiment method, a multi-layer football carcass assembly is formed. First, a bladder layer is formed by injection or compression molding of an elastomer, such as butyl rubber or any other rubber molding material. This is designated as step 100. Although butyl rubber is preferred, nearly any other rubber or blend of rubbers can be used, such as for example, acrylic rubber, butadiene rubber, butyl rubber, chlorobutyl rubber, chlorinated polyethylene rubber, chlorosulphonated polyethylene rubber, epichlorhydrin rubber, ethylene acrylic rubber, ethylene propylene rubber, fluoroelastomers, hydrogenated nitrile rubber, isoprene rubber, natural rubber, nitrile rubber, perfluoro elastomers, polychloroprene rubber, polynorbornene rubber, polysulphide rubber, polyurethane rubber, silicone and fluorosilicone rubber, styrene butadiene rubber, and tetra-flouroethylene/propylene rubber.

Next, a fibrous reinforcement layer is formed about the bladder layer. The fibrous layer can include a collection of woven filaments or strand material extending throughout a polymeric binder or matrix. This is designated as step 200. The fibrous layer is formed by winding one or more fibers, natural or synthetic, in a known manner about the bladder layer. Winding is generally performed while the bladder is at least partially inflated. It is also contemplated to utilize a non-wound fibrous layer either alone or in conjunction with a wound layer.

A lacing base, such as for example utilizing a layer of fabric is positioned and/or secured on the fibrous reinforcement layer. This is designated as step 300. The lacing fabric base preferably includes a slit-like opening and apertures for acceptance of the laces. The resulting assembly is referred to herein as the carcass and designated as 400. The lacing base can be formed from nearly any material including for example, a nonwoven material or fabric. The base can also be formed from a thin planar member such as including a cellulose material. Alternately or in addition, polymeric materials may be used to form the lacing base.

FIG. 5 illustrates additional steps of the preferred embodiment method for forming an intermediate football. At this point in the process, an optional layer of rubber or elastomer, and preferably which is a foam, such as an SBR (styrene butadiene rubber) foam, can optionally be applied to the carcass. This is designated as step 500. Although an SBR foam is preferred, a wide array of other foamed or cushioning materials can be utilized. Generally, any material that upon deformation returns to its previous shape or volume could be suitable. Thus, elastomers are used. Nor is it necessary that the layer be formed from a foamed material. An elastic non-foamed material may also be suitable. The foamed layer can be formed by applying a coating of a material onto the reinforcement layer, and then foaming the applied material in-situ. Alternately, that layer can be formed by applying or depositing a foamed material. If the material foams in-situ, it is preferred that foaming occurs, or primarily occurs, during or after application of heat in the bonding of cover panels described herein. The term “foamed material” includes materials that are already foamed upon application to the carcass, and materials that are not yet foamed upon application to the carcass, such as for example, materials that foam in-situ.

Application of the seam material to the mold or carcass is designated as step 600. Preferably, this can be performed by placing various strips or thin layers of seam material or seam members into a carcass mold. The strips are placed in or upon the mold so that they are adjacent, and preferably overlie the channels defined in the molding surface. The carcass with the fibrous reinforcement layer or the optional additional foam layer, is positioned within the carcass mold containing the strips. Alternately, the strips are placed upon the carcass. The outwardly projecting seams are then formed by molding the resulting assembly. This is designated as step 650. Preferably, the seams are formed by heat and pressure applied to the mold containing the carcass and strips or seam precursor, thereby securing the strips to the carcass and at least partially melting the seams and causing the material to flow into channels defined in the molding surfaces to thereby form the noted seams. Preferably, the seams project outwardly or protrude from the outer surface of the carcass. The seam materials can include any material that upon heating to the molding temperature, flows, or otherwise tends to bond and secure the resulting seams to the underlying carcass. Preferably, the seam material is an elastomer or rubber. The seam materials can include additional adhesives, elastomers, rubbers as previously noted, or thermally activated materials. Preferably, the seam materials include a coloring agent or pigment such as carbon black so that the resulting seams in the finished football are black in color. During the application of heat and pressure, it is preferred that the rubber materials in the carcass being formed undergo vulcanization. A preferred molding configuration for forming seams is depicted in FIG. 7, and is described in greater detail herein.

Most preferably, in yet another alternate embodiment, after forming the football carcass, i.e. bladder with windings, one or more rubber or other moldable elastomer layers are placed in, and generally upon, the molding surfaces of a mold. As will be recalled, preferably, the molding surface defines a plurality of channels or depressions that enable the formation of the seams described herein. Preferably, the rubber layers cover the entirety of the molding surface. The carcass is then placed in the mold such that the rubber layer(s) are disposed between the carcass and the molding surface. Alternately, the rubber layer(s) could be placed upon or otherwise about the carcass outer surface, and the resulting assembly placed in the mold. Upon application of sufficient heat and pressure, the rubber material flows into the channels or depressions defined in the molding surface and thereby forms the noted seams. Although the term “rubber” is used in referring to the layer(s) of material placed in, and generally upon, the molding surfaces, it will be understood that this material corresponds to the previously described seam material. Accordingly, this material can include any material that upon heating to the molding temperature, flows, or otherwise adopts the shape of the channels or depressions defined in the molding surface.

After formation of outwardly projecting seams, i.e. step 650 in FIG. 5, cover panels are preferably attached to the assembly. Next, a collection of, for example 4 or 5, cover panels are selected or formed for subsequent placement along the outer surface of the carcass, and specifically, along the carcass outer layer or on the rubber layer if used. The number of cover panels may range in number higher or lower, such as from 2 to 10 or more. The cover panels can be either leather, simulated leather, or other material. It is preferred that leather panels be used. The collection of cover panels are then placed along the outer surface of the carcass and along edge portions of the seam materials. The panels are spaced apart from one another by a previously applied strip or line of seam material such that a simulated seam appears between adjacent panels. Preferably, the cover panels 70 are separated by a seam, such as outwardly extending seam 61 schematically shown in FIG. 3A. Preferably, the cover panels are free of adhesive. However, the tacky nature of the underlying carcass and seam materials is sufficient to retain the positions of the panels upon placement. Placement of cover panels is made such that a space is defined between corresponding edges of adjacent cover panels. Again, as previously noted, it is preferred that an outwardly projecting seam separates adjacent cover panels. This placement step is designated as step 700. The seam width may range for example, from about 0.5 mm to about 10 mm, preferably from about 1.5 mm to about 6 mm, and most preferably from about 2 mm to about 4 mm. The seams can be further formed or shaped upon heating or further molding the assembly such that the seam material flows into the seam regions and thus occupies the space between adjacent cover panels.

In certain embodiments, the cover panels and/or the seam materials are applied onto a “wet” or flowable layer of the optional foam material. The cover panels are secured or otherwise laminated to the carcass. Preferably, this is achieved by heating or subjecting the assembly to a molding operation to securely bond the cover panels to the foam layer, as that layer sets. Application of heat and/or pressure is preferably used to laminate the cover panels to the carcass. This is designated as step 800, and the intermediate football that is formed is designated as 900.

Referring to FIG. 6, preferably after application of the cover panels to the carcass, or layer of foam, apertures are formed in a region of the cover panels of the intermediate football 900. Preferably, one set of apertures is formed along an edge of a first cover panel, and another set of apertures is formed along a corresponding edge of an adjacent second cover panel. A slit is optionally formed in the layer of foam (if that layer is used), between the two cover panels having the noted apertures formed therein. It is important that the apertures and optional slit only extend through the thickness of the cover panels, the foam layer, and the lacing fabric base, i.e. the strip of cloth. That is, preferably the apertures and slit do not extend within the fibrous layer and the bladder layer. As will be recalled, the lacing fabric base has the holes and slit already formed in it. However, in an alternate preferred aspect, the process could form the apertures and slit in the lacing fabric base when those openings are being formed in the cover panels and carcass. The preferred process can also utilize cover panels having apertures already formed therein. That is, prior to application of the cover panels to the carcass or foamed layer, a plurality of apertures are defined in two cover panels, each set along a mating edge of a respective panel.

Lastly, lacing is inserted into the apertures. This is designated as step 1000. A wide array of lacing types and configurations can be used. Prior art laces or lacing configurations can be used. However, it is preferable in certain embodiments that the lacing exhibit a frictionally enhanced surface to promote gripping.

Throughout the process, a valve body previously formed in the bladder in a conventional manner, is aligned and exposed through an aperture in the cover assembly. The valve aperture can be formed in the designated cover panel at any point in the process.

Ball markings and striping are applied. This is designated as step 1100. Conventional ball markings and/or striping can be utilized. In certain embodiments, an integral one-piece striping member can be affixed to the outer surface of the ball, or applied within channels defined along the ball cover. Such striping members can also be sewn or stitched to the cover panels. The final football is designated as 1200.

FIG. 7 is a detailed schematic cross-sectional view of a molding assembly 2000 during formation of an intermediate ball assembly. Generally, the molding assembly is sized and adapted to form a football. The assembly 2000 comprises a carcass mold 2100 that defines a recessed molding surface 2110. The molding surface 2110 defines at least one channel or further recessed region 2112 adapted to form an outwardly projecting seam as described herein. Preferably, the collection of recessed channels extend from one end of the mold to another, opposite end of the mold. The ball assembly is formed by placing strips of seam material 2060 over the channels, and preferably in contact with the molding surface 2110. A previously formed intermediate ball assembly including a bladder 2020 and a layer of a fibrous reinforcement component 2030, is positioned in the mold and generally in contact with the seam material strips 2060. Upon application of sufficient heat and/or pressure, the seam material 2060 flows and generally adopts the shape of the channel 2112. Thus, the previously described seams are readily formed and in a manner which avoids the problems of ensuring alignment of preformed ribs or panels that are used to form seams.

FIG. 8 illustrates the intermediate ball assembly formed from the molding assembly in FIG. 7, and placement of cover panels 2070 on the ball assembly. Preferably, the panels 2070 are separated by the raised and outwardly projecting seams 2060. The resulting finished sports ball 2200 can undergo further finishing operations as described herein.

As will be apparent to persons skilled in the art, various modifications and adaptations of the structures and methods described above will become readily apparent without departure of the spirit and scope of the development disclosed herein. The above description merely provides a disclosure of particular embodiments of the development and is not intended for the purposes of limiting the same thereto. Rather, it is recognized that one skilled in the art could conceive alternative embodiments that fall within the scope of the development. 

1. A method of forming a football, the method comprising: forming a bladder adapted for use in a football; depositing a reinforcement layer on the bladder to thereby form a football carcass; providing a molding assembly having a molding surface that defines a plurality of recessed channels, each channel adapted to form an outwardly projecting seam; positioning a layer of a seam material between the molding surface and the carcass, and such that the layer of the seam material is immediately adjacent to a recessed channel; applying heat to the seam material thereby causing that material to adhere to the carcass and flow into an adjacent recessed channel and form an outwardly projecting seam; securing a plurality of cover panels to the carcass, wherein adjacent cover panels are separated by the outwardly projecting seam.
 2. The method of claim 1 wherein the application of heat is accompanied by applying pressure to the seam material positioned between the carcass and the molding surface.
 3. The method of claim 1 wherein the layer of seam material entirely covers the molding surface.
 4. The method of claim 1 wherein the seam material is a rubber, and application of heat is sufficient to at least partially vulcanize the rubber.
 5. The method of claim 1 further comprising: after depositing the reinforcement layer on the bladder to thereby form the football carcass, applying a lacing base to the reinforcement layer.
 6. The method of claim 5 wherein at least one of the cover panels defines a plurality of apertures, the method further comprising: inserting a lacing into the apertures.
 7. The method of claim 1 further comprising: applying at least one of (i) ball markings and (ii) striping to the at least one cover panel.
 8. The method of claim 1 wherein the number of cover panels is 4 to
 5. 9. The football produced by the method of claim
 1. 10. A method of forming a football, the method comprising: providing a first molding surface; molding a bladder on the first molding surface; forming a fibrous reinforcement layer on the bladder; applying a lacing base to the reinforcement layer to thereby form a carcass; providing a second molding surface defining a plurality of recessed channels adapted to form seams in the football; applying a layer of a seam material onto at least one of the second molding surface and the carcass, such that the seam material is adjacent to a recessed channel; applying at least one of heat and pressure to the layer of the seam material to thereby cause the seam material to at least partially flow into the recessed channel and thereby form an outwardly projecting seam; applying a plurality of cover panels onto the underlying carcass and alongside the seam; inserting laces into apertures defined in at least one cover panel; and applying markings or striping to the cover panels to thereby form the football.
 11. The method of claim 10 wherein the number of cover panels is 4 to
 5. 12. The method of claim 10 wherein the cover panels are formed from natural leather or synthetic leather.
 13. The method of claim 10 wherein the seams extend longitudinally from one end of the carcass to another end.
 14. The method of claim 10 wherein the lacing base defines a slit and a plurality of apertures adapted to receive a lacing.
 15. The method of claim 10 wherein the lacing base is formed from a woven fabric.
 16. The football produced by the method of claim
 10. 17. A method of forming a football comprising: forming an inflatable bladder; forming a reinforcement layer on the bladder to thereby form a carcass; providing a molding assembly sized and adapted to form a football, the molding assembly having a molding surface that defines a plurality of recessed channels extending from one end of the mold to another, opposite end of the mold; positioning a layer of a moldable material onto the molding surface such that the entirety of the molding surface is covered by the moldable material; placing the carcass in the molding assembly such that the layer of molding material is disposed between the carcass and the molding surface; closing the molding assembly; applying heat and pressure to the carcass and the moldable material such that the material flows into the recessed channels defined in the molding surface to thereby form outwardly extending projections along the resulting intermediate football assembly; removing the intermediate football assembly from the molding assembly; securing a plurality of cover panels to the intermediate football assembly such that an outwardly extending projection separates adjacent cover panels.
 18. The method of claim 17 wherein the layer of moldable material is selected from the group consisting of butyl rubber and natural rubber.
 19. The method of claim 18 wherein the step of applying heat and pressure is performed such that the material is at least partially vulcanized.
 20. The method of claim 17 wherein the layer of moldable material, prior to positioning onto the molding surface is in the form of four panels.
 21. The football produced by the method of claim
 17. 